Ground Rubber Tire Proppant for Hydraulic Fracturing
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Solution Overview
Problem
Current hydraulic fracturing proppants, such as frac sand and resin-coated proppants, face issues like fast settling, embedment in reservoir walls, and the formation of fines, which reduce conductivity and pose environmental hazards due to resin degradation.
Innovation Solution
Incorporating ground rubber tire particles as a proppant in hydraulic fracturing compositions, which provide enhanced mechanical and chemical stability, control over thermal degradability, and improved conductivity while being environmentally friendly and non-toxic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If frac sand is used as proppant, then it is inexpensive and readily available, but it settles quickly and embeds in reservoir walls reducing conductivity
Solution Approach 1:
The patent combines frac sand particles with a deformable resin coating to create a composite proppant structure. The resin-coated proppant (RCP) integrates the low cost and availability of frac sand with the conductivity-enhancing properties of the deformable resin coating, which prevents embedment and maintains fracture width.
Solution Approach 2:
The deformable resin coating acts as a flexible shell around the frac sand core particle. This thin film deforms under closure stress to redistribute forces and prevent the sand particle from embedding into the reservoir wall, thereby maintaining conductivity while using inexpensive frac sand.
2Reliability
If resin-coated proppants are used, then conductivity and fracture width are improved, but resin degradation causes environmental hazards
Solution Approach 1:
The patent modifies the chemical composition and thermal stability parameters of the resin coating by selecting high-temperature stable deformable resins. This parameter change allows the coating to maintain its integrity and protective function at elevated downhole temperatures, preventing degradation and environmental hazards while preserving conductivity benefits.
Solution Approach 2:
The patent uses biodegradable or environmentally benign resin materials that can safely degrade after serving their protective function. This allows the coating to be temporary (short-living) in terms of environmental persistence while maintaining its protective role during the critical production period.
3Reliability
If deformable resin coating is applied, then closure stress is redistributed and fines formation is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent employs self-coating or self-assembling resin systems that automatically form uniform coatings on proppant particles without requiring complex multi-step manufacturing processes. The resin may self-adhere to particles or self-level during the coating process, reducing manufacturing complexity while achieving the desired deformable protective layer.
4Productivity
If proppants are used to hold fractures open, then fluid flow is improved, but proppant crushing under stress generates fines that decrease conductivity
Solution Approach 1:
The deformable resin coating serves as a pre-applied cushion layer on the proppant surface. When closure stress is applied, this cushioning layer deforms first to absorb and redistribute stress, protecting the underlying proppant core from crushing and preventing fines generation that would reduce conductivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of ground rubber tire particles in hydraulic fracturing compositions enhances proppant conductivity, stability, and environmental safety, addressing the limitations of traditional proppants and offering a renewable resource for the growing fracking industry.
Implementation Method 1
The RCP coating deforms to collectively redistribute closure stress forces across a greater area, which exerts a greater resistance to crushing and fines formations
Implementation Method 2
Frac sand inheres several disadvantages, however, which limit its use as a proppant. Examples of such disadvantages include fast settling
Data Source
AI summary
A composition for hydraulic fracking is provided, which includes a proppant particle and a ground rubber tire particle.